116478 - AL8000HT Light Tower
-
Upload
prejit-radhakrishna -
Category
Documents
-
view
219 -
download
0
Transcript of 116478 - AL8000HT Light Tower
-
8/11/2019 116478 - AL8000HT Light Tower
1/100
Service Manual
First Edition
Rev A
Part No. 116478
September 2008
AL8000HTTM
-
8/11/2019 116478 - AL8000HT Light Tower
2/100
September 2008
AL8000HT Light Tower Part No. 116478ii
Important
Read, understand and obey the safety rules andoperating instructions in the appropriate Operator's
Manual on your machine before attempting anymaintenance procedure.
Basic mechanical, hydraulic and electricalskills are required to perform most procedures.
However, several procedures require specializedskills, tools, lifting equipment and a suitable
workshop. In these instances, we stronglyrecommend that maintenance and repair be
performed at an authorized Terex dealerservice center.
Technical Publications
Terex has endeavored to deliver the highest degreeof accuracy possible. However, continuous
improvement of our products is a Terex policy.Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Terex of errorsand send in suggestions for improvement. Allcommunications will be carefully considered for
future printings of this and all other manuals.
Copyright 2008 by Terex
Terex Rock Hill590 Huey RoadRock Hill, SC. 29730
116478 Rev A September 2008First Edition, First Printing
" Printed on recycled paper
Printed in U.S.A.
Contact Us:
Internet: www.genielift.com
e-mail: [email protected]
Introduction
-
8/11/2019 116478 - AL8000HT Light Tower
3/100
September 2008
Part No. 116478 AL8000HT Light Tower
Serial Number Legend
iii
How to Read Your Serial Number
-
8/11/2019 116478 - AL8000HT Light Tower
4/100
Section 1 Safety Rules September 2008
AL8000HT Light Tower Part No. 116478
Danger
Failure to obey the instructions and safety rules
in this manual and the Terex AL8000HT Operator'sManualon your machine will result in death or
serious injury.
Many of the hazards identified in the operatorsmanual are also safety hazards when maintenanceand repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturers instructions and safety rules
- employers safety rules and worksite
regulations- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Safety Rules
iv
-
8/11/2019 116478 - AL8000HT Light Tower
5/100
-
8/11/2019 116478 - AL8000HT Light Tower
6/100
September 2008
AL8000HT Light Tower Part No. 116478vi
Table of Contents
Introduction
Important Information ........................................................................................................... ii
How to Read Your Serial Number ........................................................................................ iii
Parts Stocking List ............................................................................................................. x
How to Order Parts .............................................................................................................xi
Service Parts Fax Order Form ...........................................................................................xii
Section 1 Safety Rules
General Safety Rules .................................................................................................. iv
Section 2 Rev Specifications
A Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 1
Hydraulic Oil Specifications ................................................................................... 2 - 2
Hydraulic Component Specifications ...................................................................... 2 - 2
Manifold Component Specifications ....................................................................... 2 - 3
Kubota D1105-E Engine ......................................................................................... 2 - 4
Kubota V1505-E Engine ........................................................................................ 2 - 5Isuzu 4LE1 Engine................................................................................................. 2 - 6
Generator Specifications........................................................................................ 2 - 7
Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 8
SAE and Metric Fasteners Torque Charts.............................................................. 2 - 9
Genset Torque Specifications .............................................................................. 2 - 10
Section 3 Rev Scheduled Maintenance Procedures
Introduction............................................................................................................ 3 - 1
Pre-delivery Preparation Report .............................................................................. 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
A Checklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Perform Function Tests ................................................................................ 3 - 8
-
8/11/2019 116478 - AL8000HT Light Tower
7/100
September 2008
Part No. 116478 AL8000HT Light Tower
TABLE OF CONTENTS
A-4 Perform Engine Maintenance - Isuzu Models ............................................... 3 - 9
Section 3 Rev Scheduled Maintenance Procedures,continued
A-5 Perform Generator Maintenance ................................................................... 3 - 9
A-6 Perform Axle Maintenance ......................................................................... 3 - 10
A-7 Perform 30 Day Service ............................................................................. 3 - 10
A-8 Perform Engine Maintenance ..................................................................... 3 - 11
A-9 Perform Hitch Maintenance ........................................................................ 3 - 11
A-10 Grease the Turntable RotationBearing and Rotate Gear ............................. 3 - 12
A-11 Perform Engine Maintenance - Kubota Models ........................................... 3 - 13
A-12 Perform Engine Maintenance - Kubota Models ........................................... 3 - 13
A Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 14
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 14
B-3 Inspect the Tires and Wheels (including lug nut torque).............................. 3 - 15
B-4 Perform Hydraulic Oil Analysis................................................................... 3 - 15
B-5 Perform Engine Maintenance - Isuzu Models ............................................. 3 - 16
B-6 Perform Generator Maintenance ................................................................. 3 - 16
B-7 Perform Hitch Maintenance ........................................................................ 3 - 17
B-8 Perform Engine Maintenance - Kubota Models ........................................... 3 - 17
B-9 Perform Axle Maintenance ......................................................................... 3 - 17
A Checklist C Procedures
C-1 Inspect the Tower Extend/Retract Cables and Pulleys ............................... 3 - 19
C-2 Perform Engine Maintenance ..................................................................... 3 - 19
C-3 Perform Axle Maintenance ......................................................................... 3 - 20
C-4 Perform Engine Maintenance - Isuzu Models ............................................. 3 - 20
C-5 Perform Engine Maintenance - Kubota Models ........................................... 3 - 21
A Checklist D Procedures
D-1 Perform Engine Maintenance - Kubota Models ........................................... 3 - 22
D-2 Check the Tower Rotation Bearing Bolts .................................................... 3 - 22
D-3 Replace the Hydraulic Return Filter ............................................................ 3 - 23
D-4 Perform Engine Maintenance - Isuzu Models ............................................. 3 - 24
vii
-
8/11/2019 116478 - AL8000HT Light Tower
8/100
September 2008
AL8000HT Light Tower Part No. 116478viii
TABLE OF CONTENTS
D-5 Perform Engine Maintenance - Isuzu Models ............................................. 3 - 24D-6 Perform Engine Maintenance ..................................................................... 3 - 25
Section 3 Rev Scheduled Maintenance Procedures,continued
D-7 Perform Generator Maintenance ................................................................. 3 - 25
D-8 Perform Tongue Jack and Outrigger Jack Maintenance ............................. 3 - 26
D-9 Perform Axle Maintenance ......................................................................... 3 - 26
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 27
E-2 Perform Engine Maintenance - Kubota Models ........................................... 3 - 28
E-3 Perform Engine Maintenance - Kubota Models ........................................... 3 - 29
E-4 Perform Generator Maintenance ................................................................. 3 - 29
E-5 Perform Generator Maintenance ................................................................. 3 - 30
Section 4 Rev Repair Procedures
Introduction............................................................................................................ 4 - 1
A Lighting
1-1 Lighting ........................................................................................................ 4 - 2
A Light Bar Components
2-1 Light Bar ...................................................................................................... 4 - 4
2-2 Light Bar Lift Cylinder ................................................................................... 4 - 5
A Tower Components
3-1 Plastic Cable Track ...................................................................................... 4 - 7
3-2 Tower Assembly .......................................................................................... 4 - 7
3-3 Tower Lift Cylinder ..................................................................................... 4 - 10
3-4 Tower Extension Cylinder ........................................................................... 4 - 11
3-5 Tower Rotation Motor ................................................................................. 4 - 12
A Kubota D1105-E/V1505-E Engine4-1 Timing Adjustment ..................................................................................... 4 - 13
4-2 Glow Plugs................................................................................................. 4 - 13
4-3 Coolant Temperature and Oil Pressure Switches ........................................ 4 - 13
A Isuzu 4LE1 Engine
5-1 Timing Adjustment ..................................................................................... 4 - 14
-
8/11/2019 116478 - AL8000HT Light Tower
9/100
September 2008
Part No. 116478 AL8000HT Light Tower
5-2 Glow Plugs................................................................................................. 4 - 145-3 Coolant Temperature and Oil Pressure Switches ........................................ 4 - 14
Section 4 Rev Repair Procedures,continued
A Generator
6-1 Generator ................................................................................................... 4 - 15
A Chassis Components
7-1 Ground Controls ......................................................................................... 4 - 19
7-2 Light Ballast ............................................................................................... 4 - 20
7-3 Fuel Tank ................................................................................................... 4 - 21
8-1 Function Manifold Components .................................................................. 4 - 23
8-2 Valve Adjustments - Function Manifold ...................................................... 4 - 24
Section 5 Rev Troubleshooting
Introduction............................................................................................................ 5 - 1
A Troubleshooting Guide ........................................................................................... 5 - 2
A Light Fixture Troubleshooting ................................................................................. 5 - 5
Section 6 Rev Schematics
A Introduction ............................................................................................................ 6 - 1
A Electrical Symbols Legend .................................................................................... 6 - 2
A Hydraulic Symbols Legend .................................................................................... 6 - 3
A Electrical Schematic - Machine Functions ............................................................. 6 - 4
A DC Electrical Schematic - Control Box and Engine - Isuzu Models ....................... 6 - 5
A DC Electrical Schematic - Control Box and Engine - Kubota Models .................... 6 - 6
A DC Electrical Schematic - Control Box and Engine - with Autostart Option ........... 6 - 7
A AC Electrical Schematic - Standard Models with 4 Lights ...................................... 6 - 8
A AC Electrical Schematic - Standard Models with 6 Lights ...................................... 6 - 9
A AC Electrical Schematic - Standard Models with 8 Lights .................................... 6 - 10
A AC Electrical Schematic - Autostart Models with 4 Lights.................................... 6 - 11
A AC Electrical Schematic - Autostart Models with 6 Lights.................................... 6 - 12
A AC Electrical Schematic - Autostart Models with 8 Lights.................................... 6 - 13
A Receptacle Wiring Diagrams ................................................................................ 6 - 14
A Hydraulic Schematic ............................................................................................ 6 - 15
ix
TABLE OF CONTENTS
-
8/11/2019 116478 - AL8000HT Light Tower
10/100
September 2008
AL8000HT Light Tower Part No. 116478x
Required PartsThe following parts are required to perform
maintenance procedures as outlined in theTEREX AL8000HT Parts and Service Manual.
Description Part No.
Kubota Models
Oil Filter .............................................................. 866050Air Filter .............................................................. 866127Fuel Filter ...........................................................839200V-belt ................................................................. 839209
Isuzu Models
Oil Filter .............................................................. 868075Air Filter .............................................................. 834460Fuel Filter ...........................................................868137V-belt ................................................................. 868067
Parts Stocking List
Manuals
TEREX Corporation offers the following manuals for
these models:
Title Part No.
TEREX AL8000HT Operator's Manual, ..............114426
First Edition
TEREX AL8000HT Part's Manual, .....................116447
First Edition
TEREX AL8000HT Service Manual, ..................116478
First Edition
Newage Generator Manual ................................830001
Leroy Somer Manual ..........................................116118
Isuzu Engine Manual .........................................116133
Kubota Engine Manual.......................................893020
Axis Manual ........................................................116117
Marathon Manual ...............................................116188
-
8/11/2019 116478 - AL8000HT Light Tower
11/100
September 2008
Part No. 116478 AL8000HT Light Tower
Machine Information
Model
Serial Number
Date of Purchase
Authorized TEREX Distributor
Phone Number
Please be prepared with the following informationwhen ordering replacement parts for your TEREXproduct:
Machine model number
Machine serial number
Terex part number
Part description and quantity
Purchase order number
"Ship to" address
Desired method of shipment
Name and telephone number of the
authorized TEREX Distributor in your area
Use the Service Parts Fax Order Form on thenext page and fax your order to our Parts
Department.
If you don't know the name of your authorized
distributor, or if your area is not currently servicedby an authorized distributor, please call TEREXCorporation.
How To Order Parts
Genie Industries18340 NE 76th Street
P.O. Box 97030
Redmond, WA 98073-9730
Telephone (877) 367-5606
Fax (888) 274-6192
genieindustries.com
xi
-
8/11/2019 116478 - AL8000HT Light Tower
12/100
September 2008
AL8000HT Light Tower Part No. 116478
Part Number Description Quantity Price
All backordered parts will be shipped when available via the same ship method as the original order unlessnoted below:
o Ship complete order only - no backorders
o Ship all available parts and contact customer on disposition of backordered parts
o Other (please specify)
Please fill out completely
Date _________________________________ Account Number _______________________________
Your Name ______________________________ Your Fax Number ______________________________________________________________ Your Phone Number ___________________________
Bill To _________________________________ Ship To ___________________________________
_________________________________ ___________________________________
_________________________________ ___________________________________
_________________________________ ___________________________________
Purchase Order Number ____________________ Ship Via ___________________________________
Model(s) ______________________________________________________ Serial No.(s) _________________
Optional Equipment ___________________________________________________________________________
FORTEREX USEONLY
Order Number ______________ Origin Code ________________ Comments _________________________
Date Scheduled ____________ Ship Condition _____________ __________________________________
Order Total ________________ Terms Code _______________ __________________________________
r
e m o v e t h i s p a g e a n d m a k e c o p i e s
r e m o v e t h i s p a g e a n d m a k e c o p i e s
Service Parts fax Order FormFAX TO: (888) 274-6192 OR TOLL FREE: 877-367-5606
-
8/11/2019 116478 - AL8000HT Light Tower
13/100
Section 2 Specifications
REV A
September 2008
Part No. 116478 AL8000HT Light Tower 2 - 1
Machine SpecificationsLights
Type: BT-37 Metal Halide, 1000 watt
Total lighting wattage
4 lights 4000 watts
8 lights 8000 watts
Axle
Axle load capacity, maximum 4200 lbs
1905 kg
Fluid capacities
Hydraulic tank capacity 1.4 gallons
5.3 liters
Hydraulic system capacity 2 gallons
(including tank) 7.6 liters
Single fuel tank 30 gallons
114 liters
Dual fuel tanks 60 gallons
227 liters
Tires and wheels (U.S. models)
Tire size ST205/75R15
Load range C
Lug nut torque, dry 80 ft-lbs
108 Nm
Tire pressure, maximum (cold) 50 psi
3.4 bar
Tires and wheels (Australia models)
Tire size 7.5R16 C 112/110L
Lug nut torque, dry 80 ft-lbs
108 Nm
Tire pressure, maximum (cold) 75 psi
5.2 bar
Specifications
Performance SpecificationsTongue weight, maximum 350 lbs
159 kg
Run time, full load
Kubota D1105 (8kW) @ .82 Gallons per hour
Single full fuel tank 36.5 hours
Dual full fuel tanks 73 hours
Run time, full load
Kubota V1505 (12kW) @ 1.1 Gallons per hour
Single full fuel tank 27.25 hours
Dual full fuel tanks 54.5 hours
Run time, full load
Isuzu 4LE1 (20kW) @ 1.8 Gallons per hour
Single full fuel tank 16.5 hours
Dual full fuel tanks 33 hours
Towing speed, maximum 62 mph
100 km/h
Function speeds
Boom up 12 to 24 seconds
Boom down 12 to 21 seconds
Boom extend 17 to 37 seconds
Boom retract 13 to 27 seconds
Light bar up 18 to 30 seconds
Light bar down 14 to 24 seconds
Tower rotate, 359 31 to 68 seconds
Continuous improvement of our products is aTerex policy. Product specifications are subjectto change without notice.
For operational specifications, refer to theOperator's Manual.
-
8/11/2019 116478 - AL8000HT Light Tower
14/100
Section 2 Specifications
REV A
September 2008
2 - 2 AL8000HT Light Tower Part No. 116478
Hydraulic Oil SpecificationsHydraulic Oil Specifications
Hydraulic oil type Chevron Rando HD Premium MV
Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulicsystems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Continued use of Chevron AviationA hydraulic fluid when ambienttemperatures are consistently
above 32F / 0C may result incomponent damage.
Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below0F / -18C.
Note: Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205F / 96C.
Note: Terex specifications require additionalequipment and special installation instructions for
the approved optional fluids. Consult the TerexService Department before use.
Hydraulic ComponentSpecifications
Function pump
Type: Fixed displacement gear pump
Displacement 0.056 cu in
per revolution 0.92 cc
Flow rate @ 3200 psi 0.6 gpm
2.27 L/min
System relief pressure 3200 psi
220.6 bar
Function manifold
Light bar up/down 0.2 gpm
flow regulator 0.76 L/min
Tower rotate relief 1200 psi
valve pressure 82.7 bar
Hydraulic filter
Hydraulic tank Beta 10 200
return filter with 25 psi / 1.7 bar bypass
Continuous improvement of our products is aTerex policy. Product specifications are subjectto change without notice.
SPECIFICATIONS
-
8/11/2019 116478 - AL8000HT Light Tower
15/100
Section 2 Specifications
REV A
September 2008
Part No. 116478 AL8000HT Light Tower 2 - 3
Manifold ComponentSpecifications
Plug torque
SAE No. 2 36 in-lbs / 4 Nm
SAE No. 4 10 ft-lbs / 13 Nm
SAE No. 6 14 ft-lbs / 19 Nm
SAE No. 8 38 ft-lbs / 51 Nm
SAE No. 10 41 ft-lbs / 55 Nm
SAE No. 12 56 ft-lbs / 76 Nm
Valve Coil Resistance
Note: The following coil resistance specifications are at
an ambient temperature of 68F / 20C. As valve coil
resistance is sensitive to changes in air temperature,
the coil resistance will typically increase or decrease by
4% for each 18F / 20C that your air temperature
increases or decreases from 68F / 20C.
Valve coil specifications
3 position 4 way solenoid valve, 10V DC 6
(schematic items B, C, E and G)
Machine Torque SpecificationsTower rotation assembly
Rotate bearing mounting bolts, lubricated1/2 -13 SHC bolts 95 ft-lbs
129 Nm5/8 -11 SHC bolts 195 ft-lbs
264 Nm
Rotation motor mounting bolts, dry 75 ft-lbs1/2 -13, GR 5 102 Nm
Rotation motor mounting bolts, lubricated 57 ft-lbs1/2 -13, GR 5 77 Nm
Generator
Generator case to engine 25 ft-lbs
bell housing fasteners 34 Nm
Generator vibration 75 ft-lbs
isolator fasteners 102 Nm
Flex plate to flywheel 25 ft-lbs
34 Nm
Continuous improvement of our products is aTerex policy. Product specifications are subjectto change without notice.
SPECIFICATIONS
-
8/11/2019 116478 - AL8000HT Light Tower
16/100
Section 2 Specifications
REV A
September 2008
2 - 4 AL8000HT Light Tower Part No. 116478
Kubota D1105-E EngineDisplacement 68.53 cu in
1.12 liters
Number of cylinders 3
Bore and stroke 3.07 x 3.09 inches
78 x 78.4 mm
Horsepower, continuous 13.6 @ 1800 rpm
10.1 kW
Firing order 1 - 2 - 3
Compression ratio 23:1
Compression pressure 412 to 469 psi
28.4 to 32.3 bar
Engine speed 1800 rpm
Governor centrifugal mechanical
Valve clearance, cold 0.0057 to 0.0072 in
0.145 to 0.185 mm
Engine coolant
Capacity 3.27 quarts
3.1 liters
Lubrication system
Oil pressure 28 to 64 psi
1.93 to 4.41 bar
Oil capacity 5.4 quarts
(including filter) 5.1 liters
Oil pressure switch 7 psi
(engine shutoff pressure)
Oil viscosity requirements
Units ship with 10W-30.
Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Injection system
Injection pump make Bocsh MD mini
Injection timing 19 BTDC
Injection pump pressure 1991 psi
137 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Battery
Type 12V DC
Group 27TM
Quantity 1
Cold cranking ampere 500
Reserve capacity @ 25A rate 105 minutes
Alternator
Output 40A, 12V DC
Fan belt deflection 1/4to 3/8 inch
7 to 9 mm
SPECIFICATIONS
Continuous improvement of our products is aTerex policy. Product specifications are subjectto change without notice.
-
8/11/2019 116478 - AL8000HT Light Tower
17/100
Section 2 Specifications
REV A
September 2008
Part No. 116478 AL8000HT Light Tower 2 - 5
Kubota V1505-E EngineDisplacement 91.41 cu in
1.5 liters
Number of cylinders 4
Bore and stroke 3.07 x 3.09 inches
78 x 78.4 mm
Horsepower, continuous 17.9 @ 1800 rpm
13.4 kW
Firing order 1 - 3 - 4 - 2
Compression ratio 22:1
Compression pressure 412 to 469 psi
28.4 to 32.3 bar
Engine speed 1800 rpm
Governor centrifugal mechanical
Valve clearance, cold 0.0057 to 0.0072 in
0.145 to 0.185 mm
Engine coolant
Capacity 4.23 quarts
4 liters
Lubrication system
Oil pressure 28 to 64 psi
1.93 to 4.41 bar
Oil capacity 7.08 quarts
(including filter) 6.7 liters
Oil pressure switch 7 psi
(engine shutoff pressure)
Oil viscosity requirements
Units ship with 10W-30.
Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Injection system
Injection pump make Bocsh MD mini
Injection timing 19 BTDC
Injection pump pressure 1991 psi
137 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Battery
Type 12V DC
Group 27TM
Quantity 1
Cold cranking ampere 630
Reserve capacity @ 25A rate 105 minutes
Alternator
Output 30A, 12V DC
Fan belt deflection 1/4to 3/8 inch
7 to 9 mm
SPECIFICATIONS
-
8/11/2019 116478 - AL8000HT Light Tower
18/100
Section 2 Specifications
REV A
September 2008
2 - 6 AL8000HT Light Tower Part No. 116478
SPECIFICATIONS
Isuzu 4LE1 EngineDisplacement 133 cu in
2.179 liters
Number of cylinders 4
Bore and stroke 3.35 x 3.78 inches
85 x 96 mm
Horsepower, continuous 31.4 @ 1800 rpm
23.4kW
Firing order 1 - 3 - 4 - 2
Compression ratio 21.5:1
Engine speed 1800 rpm
Governor variable speed, mechanical
Valve clearance, cold
Intake 0.0157 in
0.4 mm
Exhaust 0.0157 in
0.4 mm
Lubrication system
Oil pressure (hot @ 1800 rpm) 64 psi
4.4 bar
Oil capacity 7.08 quarts
(including filter) 6.7 liters
Oil pressure switch 14 psi
(engine shut-off pressure) 0.96 bar
Oil viscosity requirements
Units ship with 10W-30.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operating Instructions on your machine.
Engine coolant
Capacity 4 quarts
3.8 liters
Coolant temperature switch 221 7F
(engine shut-off temperature) 105 4C
Injection system
Injection pump make Bosch, PFR ype
Injection timing 16 BTDC
Injection pump pressure 1920 psi
132.8 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Battery
Type 12V DC
Group 27TM
Quantity 1
Cold cranking ampere 630
Reserve capacity @ 25A rate 105 minutes
Alternator
Output 35A, 12V DC
Fan belt deflection 1/4to 3/8 inch
7 to 9 mm
Continuous improvement of our products is aTerex policy. Product specifications are subjectto change without notice.
-
8/11/2019 116478 - AL8000HT Light Tower
19/100
Section 2 Specifications
REV A
September 2008
Part No. 116478 AL8000HT Light Tower 2 - 7
SPECIFICATIONS
Leroy Somer LSA37M7Generator
Generator speed @ full load 60 Hz 1800 rpm
Temperature, ambient maximum 104F
40C
Power 8 kW
Capacitor (disconnected) 100 F @ 240V
Marathon 201CSA5412
Generator
Generator rpm @ full load 60 Hz 1800 rpm
Temperature, ambient maximum 104F
40C
Power 8 kW
Newage BCI164D1J195A
Generator
Generator rpm @ full load 60 Hz 1800 rpm
Temperature, ambient maximum 104F
40C
Power 12 kW
Newage BCI184E1J203A
Generator
Generator rpm @ full load 60 Hz 1800 rpm
Temperature, ambient maximum 104F
40C
Power 20 kW
Continuous improvement of our products is aTerex policy. Product specifications are subjectto change without notice.
-
8/11/2019 116478 - AL8000HT Light Tower
20/100
Section 2 Specifications
REV A
September 2008
2 - 8 AL8000HT Light Tower Part No. 116478
Hydraulic Hose and FittingTorque Specifications
Your machine is equipped with Parker Seal-Lokfittings and hose ends. Genie specifications require
that fittings and hose ends be torqued tospecification when they are removed and installed
or when new hoses or fittings are installed.
SAE O-ring Boss Port(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 40 ft-lbs / 54.2 Nm
-10 69 ft-lbs / 93.6 Nm
-12 93 ft-lbs / 126.1 Nm
-16 139 ft-lbs / 188.5 Nm
-20 172 ft-lbs / 233.2 Nm
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port(tube fitting - installed into Steel)
SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 105 ft-lbs / 142.4 Nm
-12 140 ft-lbs / 190 Nm
-16 210 ft-lbs / 284.7 Nm
-20 260 ft-lbs / 352.5 Nm
-24 315 ft-lbs / 427.1 Nm
Seal-Lok Fittings(hose end)
SAE Dash size Torque
-4 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 40 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 80 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
Seal-Lok fittings1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end hasbeen tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lokfittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They areavailable in the O-ring field service kit (Genie partnumber 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated andretained properly.
4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.
6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.
SPECIFICATIONS
-
8/11/2019 116478 - AL8000HT Light Tower
21/100
Section 2 Specifications
REV A
September 2008
Part No. 116478 AL8000HT Light Tower 2 - 9
SPECIFICATIONS
Size
(mm)
in -lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.610 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
LUBEDDRYLUBED
Class 12.9Class 4.6
DRYLUBED
METRIC FASTENER TORQUE CHART This char t is to be used as a guide only unless noted elsewhere in this manual
LUBED DRY
Class 10.9Class 8.8
DRY
SIZE THREAD
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.5
16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
5/16
3/8
7/16
1/2
1 1/2
9/16
5/8
3/4
7/8
1
11/8
11/4
LUBED
1/4
LUBED DRY LUBED DRY
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5
DRYLUBED
This chart is to be used as a guide only unless noted elsewhere in this manual
A574 High Strength
Black Oxide BoltsGrade 8
10.9 12.98.84.6
-
8/11/2019 116478 - AL8000HT Light Tower
22/100
September 2008
2 - 10 AL8000HT Light Tower Part No. 116478
Generator FT*LB
Flex Plate to Flywheel 25
Generator Case to Bellhousing 25
Genset Isolators 75
GENSET TORQUE SPECIFICATIONS
-
8/11/2019 116478 - AL8000HT Light Tower
23/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 1
September 2008
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on themaintenance of this machine.
Scheduled maintenance inspections shall becompleted daily, quarterly, semi-annually,
annually and every 2 years as specified on theMaintenance Inspection Report.
Failure to perform each procedure
as presented and scheduled couldresult in death, serious injury or
substantial damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Use only Terex approved replacement parts.
Machines that have been out of service for a
period longer than 3 months must complete thequarterly inspection.
Unless otherwise specified, perform each
maintenance procedure with the machine in the
following configuration:
Machine parked on a firm, level surface
Key switch in the off position
(manual start models)
Toggle switch in the off position(automatic start models)
Mast in the stowed position
Light switches in the off position
Wheels chocked
About This SectionThis section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safetywarnings and step-by-step instructions.
Symbols Legend
Safety alert symbolused to alert
personnel to potential personalinjury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates an imminently hazardous
situation which, if not avoided, willresult in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,could result in death or seriousinjury.
Indicates a potentially hazardous
situation which, if not avoided,may cause minor or moderate
injury.
Indicates a potentially hazardoussituation which, if not avoided,may result in property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
-
8/11/2019 116478 - AL8000HT Light Tower
24/100
Section 3 Scheduled Maintenance Procedures
3 - 2 AL8000HT Light Tower Part No. 116478
September 2008
Maintenance Symbols LegendThe following symbols have been used in thismanual to help communicate the intent of the
instructions. When one or more of the symbolsappear at the beginning of a maintenance
procedure, it conveys the meaning below.
Indicates that tools will be required toperform this procedure.
Indicates that new parts will be requiredto perform this procedure.
Indicates that a cold engine will berequired to perform this procedure.
Indicates that a warm engine will berequired to perform this procedure.
Indicates that dealer service will berequired to perform this procedure.
Pre-delivery Preparation ReportThe pre-delivery preparation report containschecklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation report
to use for each inspection. Store completed formsas required.
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a scheduledaily, quarterly, semi-annually, annual and
two year. The Scheduled Maintenance ProceduresSection and theMaintenance Inspection Reporthave been divided into five subsectionsA, B, C,
D and E. Use the following chart to determine whichgroup(s) of procedures are required to perform a
scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Semi-annually or every 500 hours A + B + C
Annually or every 1000 hours A + B + C + D
Two years or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report containschecklists for each type of scheduled inspection.
Make copies of theMaintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliancewith employer, jobsite and governmentalregulations and requirements.
SCHEDULED MAINTENANCE PROCEDURES
-
8/11/2019 116478 - AL8000HT Light Tower
25/100
Copyright2006 by TEREX Corporation. TEREX is a registered trademark of TEREXCorporation.
Rev B
TEREX Rock HillP.O. BOX 3147Rock Hill, SC 29732 USAToll Free (800) 433-3026 in U.S.A. and Canada
Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completedFunction tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Use the operators manual on your machine.
The Pre-delivery Preparation consists of completing the
Pre-operation Inspection, the Maintenance items and theFunction Tests.
Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow theinstructions in the operators manual.
If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a check
in the R box.
Legend
Y = yes, completedN = no, unable to completeR = repaired
Comments
Fundamentals
It is the responsibility of the dealer to perform thePre-delivery Preparation.
The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover if anything
is apparently wrong with a machine before it is put intoservice.
A damaged or modified machine must never be used. If
damage or any variation from factory delivered condition isdiscovered, the machine must be tagged and removed fromservice.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer'sspecifications.
Scheduled maintenance inspections shall be performed byqualified service technicians, according to themanufacturer's specifications and the requirements listed in
the responsibilities manual.
-
8/11/2019 116478 - AL8000HT Light Tower
26/100
-
8/11/2019 116478 - AL8000HT Light Tower
27/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 5
September 2008
Maintenance Inspection Report
Checklist B - Rev A Y N RB-1 Battery
B-2 Electrical wiring
B-3 Tires and wheels
B-4 Hydraulic oil analysis
B-5 Engine maintenance -
Isuzu models
B-6 Generator
maintenance
Perform quarterly:
B-7 Hitch coupler
maintenance
Perform every 400 hours:
B-8 Engine maintenance -Kubota models
Perform every 3000 miles:
B-9 Axle maintenance
Checklist C - Rev A Y N R
C-1 Extend/retract cables
and pulleys
C-2 Engine maintenance
Perform every 6000 miles:
C-3 Axle maintenance
Perform every 750 hours:
C-5 Engine maintenance -Isuzu models
Perform every 800 hours:
C-6 Engine maintenance -
Kubota models
Checklist A - Rev A Y N RA-1 Manuals and decals
A-2 Pre-operation inspect
A-3 Function tests
Perform every 8 hours:
A-4 Engine maintenance -
Isuzu models
A-5 Generator
maintenance
Perform after 10 miles:
A-6 Axle maintenance
Perform after 25 miles:
A-6 Axle maintenance
Perform after 50 miles:
A-6 Axle maintenance
Perform after 40 hours:
A-7 30 day service
Perform every 50 hours:
A-8 Engine maintenance
Perform weekly:
A-9 Hitch maintenance
Perform every 100 hours:
A-10 Grease rotation
bearing
A-11 Engine maintenance -
Kubota modelsPerform every 200 hours:
A-12 Engine maintenance -
Kubota models
Instructions
Make copies of this report to use for
each inspection.
Select the appropriate checklist(s)
for the type of inspection to be
performed.
Daily or 8 hours
Inspection: A
Quarterly or 250 hours
Inspection: A+B
Semi-annually or
500 hours
Inspection: A+B+C
Annually or
1000 hours
Inspection: A+B+C+D
Two year or
2000 hours
In sp ec ti on : A+B+C+D+E
Place a check in the appropriate box
after each inspection procedure is
completed.
Use the step-by-step procedures in
this section to learn how to perform
these inspections.
If any inspection receives an N, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
-
8/11/2019 116478 - AL8000HT Light Tower
28/100
Section 3 Scheduled Maintenance Procedures
3 - 6 AL8000HT Light Tower Part No. 116478
September 2008
Instructions
Make copies of this report to use for
each inspection.
Select the appropriate checklist(s)
for the type of inspection to be
performed.
Daily or 8 hours
Inspection: A
Quarterly or 250 hours
Inspection: A+B
Semi-annually or
500 hours
Inspection: A+B+C
Annually or
1000 hours
Inspection: A+B+C+D
Two year or
2000 hours
In sp ec ti on : A+B+C+D+E
Place a check in the appropriate box
after each inspection procedure is
completed.
Use the step-by-step procedures in
this section to learn how to perform
these inspections.
If any inspection receives an N, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Checklist D - Rev A Y N RD-1 Engine maintenance -
Kubota models
D-2 Tower rotation bearing
bolts
D-3 Hydraulic filter
D-4 Engine maintenance -
Isuzu models
Perform every 1250 hours:
D-5 Engine maintenance -
Isuzu models
Perform every 1500 hours:
D-6 Engine maintenance
D-7 Generatormaintenance
Perform annually:
D-8 Tongue and outrigger
jack maintenance
Perform every 12,000 miles:
D-9 Axle maintenance
Checklist E - Rev A Y N R
E-1 Test or replace
hydraulic oil
Perform every 3000 hours:
E-2 Engine maintenance -
Kubota models
Perform every 2 years:
E-3 Engine maintenance -
Kubota models
Perform every 4500 hours:
E-4 Generator
maintenance
Perform every 15,000 hours:
E-5 Generator
maintenance
Comments
MAINTENANCE INSPECTION REPORT
-
8/11/2019 116478 - AL8000HT Light Tower
29/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 7
REV A
September 2008
Checklist A Procedures
A-1Inspect the Manuals and Decals
Note: Terex specifications require that thisprocedure be performed daily or every 8 hours,
whichever comes first.
Maintaining the operators and safety manuals in
good condition is essential to safe machineoperation. Manuals are included with each machineand should be stored in the container provided in
the cabinet. An illegible or missing manual will notprovide safety and operational information
necessary for a safe operating condition.
In addition, maintaining all of the safety andinstructional decals in good condition is mandatory
for safe machine operation. Decals alert operatorsand personnel to the many possible hazards
associated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alert
personnel of a procedure or hazard and could resultin unsafe operating conditions.
1 Check to make sure that the operator's andsafety manuals are present and complete in the
storage container inside the cabinet.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not appropriatefor the machine or all manuals are not in good
condition or are illegible. Remove the machinefrom service until the manual is replaced.
3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.
Result: The machine is equipped with all
required decals, and all decals are legible and in
good condition.
Result: The machine is not equipped with allrequired decals, or one or more decals are
illegible or in poor condition. Remove themachine from service until the decals arereplaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Terex distributor ifreplacement manuals or decals are needed.
-
8/11/2019 116478 - AL8000HT Light Tower
30/100
Section 3 Scheduled Maintenance Procedures
3 - 8 AL8000HT Light Tower Part No. 116478
REV A
September 2008
CHECKLIST A PROCEDURES
A-2Perform Pre-operation
Inspection
Note: Terex specifications require that thisprocedure be performed every 8 hours or daily,
whichever comes first.
Completing a pre-operation inspection is essentialto safe machine operation. The pre-operation
inspection is a visual inspection performed by theoperator prior to each work shift. The inspection is
designed to discover if anything is apparently wrong
with a machine before the operator performs thefunction tests. The pre-operation inspection also
serves to determine if routine maintenanceprocedures are required.
Complete information on how to perform thisprocedure is available in the appropriate Operator'sManual. Refer to the Operator's Manual on your
machine.
A-3Perform Function Tests
Note: Terex specifications require that thisprocedure be performed every 8 hours or daily,
whichever comes first.
Completing the function tests is essential to safe
machine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine must
never be used. If malfunctions are discovered, themachine must be tagged and removed from
service.
Complete information on how to perform thisprocedure is available in the appropriate Operator's
Manual. Refer to the Operator's Manual on yourmachine.
-
8/11/2019 116478 - AL8000HT Light Tower
31/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 9
REV A
September 2008
CHECKLIST A PROCEDURES
A-4Perform Engine Maintenance -
Isuzu Models
Note: Engine specifications require that this
procedure be performed every 8 hours or daily,whichever comes first.
Required maintenance procedures and additional
engine information is available in theIsuzu 4LE1 Diesel Engine Instruction Manual
(Isuzu part number IDE-6033).
Isuzu 4LE1 Diesel Engine Instruction Manual
Terex part number 116133
A-5Perform Generator Maintenance
Note: Generator specifications require that thisprocedure be performed every 8 hours or daily,whichever comes first.
Required maintenance procedures and additionalgenerator information is available in theLeroy Somer LSA 37 Installation and
Maintenance Manual (Leroy Somer part number
3664EN-09.2005/B) OR theMarathon Installation, Operation and MaintenanceManual(Marathon part number GPN012) OR the
Newage Installation, Service and MaintenanceManual(Newage part number BCH-018).
Leroy Somer LSA 37 Installation and
Maintenance Manual
Terex part number 116118
Marathon Installation, Operation
and Maintenance Manual
Terex part number 116188
Newage Installation, Service and
Maintenance Manual
Terex part number 830001
-
8/11/2019 116478 - AL8000HT Light Tower
32/100
Section 3 Scheduled Maintenance Procedures
3 - 10 AL8000HT Light Tower Part No. 116478
REV A
September 2008
CHECKLIST A PROCEDURES
A-6Perform Axle Maintenance
Note: Axle specifications require that this procedure
be performed initially and following a wheel changeafter the first 10, 25 and 50 miles.
Proper axle maintenance, following the axle
manufacturer's maintenance schedule, is essentialto good axle performance and service life. Failure
to perform the maintenance procedures can lead topoor axle performance and component damage.
Required maintenance procedures and additionalaxle information is available in the Axis Axle
Operator Maintenance Manual included with yourmachine.
Axis Axle Operator Maintenance Manual
Terex part number 116117
A-7Perform 30 Day Service
The 30 day maintenance procedure is a one time
procedure to be performed after the first 30 days or40 hours of usage. After this interval, refer to the
maintenance tables for continued scheduledmaintenance.
1 Perform the following maintenance procedures:
B-3 Inspect the Tires, Wheels andLug Nut Torque
-
8/11/2019 116478 - AL8000HT Light Tower
33/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 11
REV A
September 2008
CHECKLIST A PROCEDURES
A-8Perform Engine Maintenance
Note: Engine specifications require that thisprocedure be performed every 50 hours.
Required maintenance procedures and additional
engine information is available in theIsuzu 4LE1 Diesel Engine Instruction Manual(Isuzu part number IDE-6033) OR the
Kubota D-1105 and V-1505 Operator's Manual
(Kubota part number 16683-89169).
Isuzu 4LE1 Diesel Engine Instruction Manual
Terex part number 116133
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
A-9Perform Hitch Maintenance
Note: Hitch specifications require that thisprocedure be performed weekly.
Required maintenance procedures and additional
hitch information is available in the Fulton CouplerUser Manual (Fulton part number F1937).
Fulton Coupler User Manual
Terex part number 150139
-
8/11/2019 116478 - AL8000HT Light Tower
34/100
Section 3 Scheduled Maintenance Procedures
3 - 12 AL8000HT Light Tower Part No. 116478
REV A
September 2008
CHECKLIST A PROCEDURES
A-10Grease the Turntable Rotation
Bearing and Rotate Gear
Note: Terex specifications require that this
procedure be performed every 100 hours ofoperation. Perform this procedure more often ifdusty conditions exist.
Frequent application of lubrication to the turntable
rotation bearing and rotate gear is essential to goodmachine performance and service life. Continued
use of an improperly greased bearing and gear willresult in component damage.
1 Lower all four outriggers to the ground and levelthe machine.
2 Remove the tower transport lock pin.
3 Raise the tower to a vertical position.
4 Locate the grease fitting on the inner race of the
bearing.
5 Pump grease into the tower rotation bearing.Rotate the tower in increments of
4 to 5 inches / 10 to 13 cm at a time and repeatthis step until the entire bearing has been
greased.
6 Remove retaining fasteners from the the piniongear guard. Remove the guard.
7 Apply grease to each tooth of the pinion gear.
8 Rotate the tower to transfer the grease from thepinion gear to the teeth of the rotation bearing.
9 Repeat steps 5 and 6 until all gear teeth are
thoroughly greased.
10 Install the pinion gear guard and securely tightenthe retaining fasteners. Do not overtighten.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
-
8/11/2019 116478 - AL8000HT Light Tower
35/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 13
REV A
September 2008
A-11Perform Engine Maintenance -
Kubota Models
Note: Engine specifications require that this
procedure be performed every 100 hours.
Required maintenance procedures and additionalengine information is available in the
Kubota D-1105 and V-1505 Operator's Manual(Kubota part number 16683-89169).
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
A-12Perform Engine Maintenance -
Kubota Models
Note: Engine specifications require that this
procedure be performed every 200 hours.
Required maintenance procedures and additionalengine information is available in the
Kubota D-1105 and V-1505 Operator's Manual(Kubota part number 16683-89169).
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
CHECKLIST A PROCEDURES
-
8/11/2019 116478 - AL8000HT Light Tower
36/100
Section 3 Scheduled Maintenance Procedures
3 - 14 AL8000HT Light Tower Part No. 116478
REV A
September 2008
B-2Inspect the Electrical Wiring
Note: Terex requires that this procedure be
performed every 250 hours or quarterly, whichevercomes first.
Maintaining electrical wiring in good condition is
essential to safe operation and good machineperformance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result inunsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact with
hot or live circuits could result indeath or serious injury. Remove all
rings, watches and other jewelry.
1 Inspect the following areas for burnt, chafed,corroded and loose wires, and for a liberal
coating of dielectric grease in the harnessconnections:
Mast Chassis
Trailer lighting
2 Inspect for a liberal coating of dielectric greasein the harness connections between thegenerator, ballasts and the mast light
assemblies.
3 Inspect the engine and generator area for burnt,chafed, corroded, pinched and loose wires, andand for a liberal coating of dielectric grease in
the harness connections.
Checklist B Procedures
B-1Inspect the Battery
Note: Terex requires that this procedure be
performed every 250 hours or quarterly, whichevercomes first.
Proper battery condition is essential to good
machine performance and operational safety.Improper fluid levels or damaged cables and
connections can result in component damage andhazardous conditions.
Electrocution hazard. Contact withhot or live circuits could result in
death or serious injury. Remove allrings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling orcontacting battery acid. Neutralize
battery acid spills with baking sodaand water.
1 Put on protective clothing and eye wear.2 Open the cabinet cover at the curb side of the
machine and locate the battery.
3 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosion on
the battery terminals and cables.
4 Be sure that the battery retainers and cableconnections are tight.
-
8/11/2019 116478 - AL8000HT Light Tower
37/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 15
REV A
September 2008
CHECKLIST B PROCEDURES
B-3Inspect the Tires and Wheels
(including lug nut torque)
Note: Terex requires that this procedure be
performed every 250 hours or quarterly, whichevercomes first.
Maintaining the tires and wheels in good
condition is essential to safe operation and good
performance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.
Bodily injury hazard. An over-
inflated tire can explode and couldresult in death or serious injury.
Tip-over hazard. Do not use
temporary flat tire repair products.
1 Check the tire tread and sidewalls for cuts,cracks, punctures and unusual wear.
2 Check each wheel for damage, bends andcracked welds.
3 Check each lug nut for proper torque. Refer to
Section 2, Specifications.
4 Check the air pressure of each tire. Refer toSection 2, Specifications.
B-4Perform Hydraulic Oil Analysis
Note: Terex requires that this procedure be
performed every 250 hours or quarterly, whichevercomes first.
Replacement or testing of the hydraulic oil is
essential for good machine performance andservice life. Dirty oil and suction strainers may
cause the machine to perform poorly and continueduse may cause component damage. Extremely
dirty conditions may require oil changes to beperformed more often.
Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels of
contamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.
Replace the oil when it fails the test. See E-1,Test or Replace the Hydraulic Oil.
-
8/11/2019 116478 - AL8000HT Light Tower
38/100
Section 3 Scheduled Maintenance Procedures
3 - 16 AL8000HT Light Tower Part No. 116478
REV A
September 2008
B-5Perform Engine Maintenance -
Isuzu Models
Note: Engine specifications require that this
procedure be performed every 250 hours orquarterly, whichever comes first.
Required maintenance procedures and additional
engine information is available in theIsuzu 4LE1 Diesel Engine Instruction Manual
(Isuzu part number IDE-6033).
Isuzu 4LE1 Diesel Engine Instruction Manual
Terex part number 116133
B-6Perform Generator Maintenance
Note: Generator specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Required maintenance procedures and additionalgenerator information is available in theLeroy Somer LSA 37 Installation and
Maintenance Manual (Leroy Somer part number
3664EN-09.2005/B) OR theMarathon Installation, Operation and MaintenanceManual(Marathon part number GPN012) OR the
Newage Installation, Service and MaintenanceManual(Newage part number BCH-018).
Leroy Somer LSA 37 Installation and
Maintenance Manual
Terex part number 116118
Marathon Installation, Operation
and Maintenance Manual
Terex part number 116188
Newage Installation, Service and
Maintenance Manual
Terex part number 830001
CHECKLIST B PROCEDURES
-
8/11/2019 116478 - AL8000HT Light Tower
39/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 17
REV A
September 2008
CHECKLIST B PROCEDURES
B-7Perform Hitch Coupler
Maintenance
Note: Hitch specifications require that this
procedure be performed quarterly.
Required maintenance procedures and additionalhitch information is available in the Fulton Coupler
User Manual (Fulton part number F1937).
Fulton Coupler User Manual
Terex part number 150139
B-8Perform Engine Maintenance -
Kubota Models
Note: Engine specifications require that this
procedure be performed every 400 hours.
Required maintenance procedures and additionalengine information is available in the
Kubota D-1105 and V-1505 Operator's Manual(Kubota part number 16683-89169).
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
B-9
Perform Axle Maintenance
Note: Axle specifications require that this procedure
be performed quarterly or every 3000 miles,whichever comes first.
Proper axle maintenance, following the axle
manufacturer's maintenance schedule, is essentialto good axle performance and service life. Failure
to perform the maintenance procedures can lead topoor axle performance and component damage.
Required maintenance procedures and additionalaxle information is available in the Axis Axle
Operator Maintenance Manual included with yourmachine.
Axis Axle Operator Maintenance Manual
Terex part number 116117
-
8/11/2019 116478 - AL8000HT Light Tower
40/100
Section 3 Scheduled Maintenance Procedures
3 - 18 AL8000HT Light Tower Part No. 116478
REV A
September 2008
This page intentionally left blank.
-
8/11/2019 116478 - AL8000HT Light Tower
41/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 19
REV A
September 2008
Checklist C Procedures
C-1Inspect the Tower Extend/
Retract Cables and Pulleys
Note: Terex requires that this procedure be
performed every 500 hours or semi-annually,whichever comes first.
Detection of damage to the cables or pulleys is
essential for safe machine operation. An unsafe
working condition exists if these components aredamaged and do not operate smoothly. Regular
inspection of this system allows the inspector toidentify changes in the operating condition that may
indicate damage.
Note: Perform this procedure with the tower in the
stowed position.
1 Lower all four outriggers to the ground and level
the machine.
2 Remove the tower transport lock pin.
3 Fully extend the tower in a horizontal direction.Tip-over hazard. The machine willtip over when the tower isextended if the outriggers are not
lowered to the ground.
4 Visually inspect the cables and components forthe following:
frayed or broken wire strands
kinks in the cable
corrosion
paint or foreign materials split or cracked cable ends
cables are on all pulleys
cables at end of adjustment range
no broken or damaged pulleys
no unusual or excessive pulley wear
all fasteners in place and secure
C-2Perform Engine Maintenance
Note: Engine specifications require that thisprocedure be performed every 500 hours orsemi-annually, whichever comes first.
Required maintenance procedures and additionalengine information is available in theIsuzu 4LE1 Diesel Engine Instruction Manual
(Isuzu part number IDE-6033) OR the
Kubota D-1105 and V-1505 Operator's Manual(Kubota part number 16683-89169).
Isuzu 4LE1 Diesel Engine Instruction Manual
Terex part number 116133
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
-
8/11/2019 116478 - AL8000HT Light Tower
42/100
Section 3 Scheduled Maintenance Procedures
3 - 20 AL8000HT Light Tower Part No. 116478
REV A
September 2008
CHECKLIST C PROCEDURES
C-3Perform Axle Maintenance
Note: Axle specifications require that this procedure
be performed every 6 months or 6000 miles,whichever comes first.
Proper axle maintenance, following the axle
manufacturer's maintenance schedule, is essentialto good axle performance and service life. Failure
to perform the maintenance procedures can lead topoor axle performance and component damage.
Required maintenance procedures and additionalaxle information is available in the Axis Axle
Operator Maintenance Manual included with yourmachine.
Axis Axle Operator Maintenance Manual
Terex part number 116117
C-4Perform Engine Maintenance -
Isuzu Models
Note: Engine specifications require that this
procedure be performed every 750 hours.
Required maintenance procedures and additionalengine information is available in the
Isuzu 4LE1 Diesel Engine Instruction Manual(Isuzu part number IDE-6033).
Isuzu 4LE1 Diesel Engine Instruction Manual
Terex part number 116133
-
8/11/2019 116478 - AL8000HT Light Tower
43/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 21
REV A
September 2008
C-5Perform Engine Maintenance -
Kubota Models
Note: Engine specifications require that this
procedure be performed every 800 hours.
Required maintenance procedures and additionalengine information is available in the
Kubota D-1105 and V-1505 Operator's Manual(Kubota part number 16683-89169).
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
CHECKLIST C PROCEDURES
-
8/11/2019 116478 - AL8000HT Light Tower
44/100
Section 3 Scheduled Maintenance Procedures
3 - 22 AL8000HT Light Tower Part No. 116478
REV A
September 2008
Checklist D Procedures
D-1Perform Engine Maintenance -
Kubota Models
Note: Engine specifications require that this
procedure be performed annually.
Required maintenance procedures and additionalengine information is available in the
Kubota D-1105 and V-1505 Operator's Manual(Kubota part number 16683-89169).
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
D-2Check the Tower Rotation
Bearing Bolts
Note: Terex requires that this procedure be
performed every 1000 hours or annually, whichevercomes first.
Maintaining proper torque on the tower rotation
bearing bolts is essential to safe machine
operation. Improper bolt torque could result in anunsafe operating condition and component damage.
1 Lower all four outriggers to the ground and level
the machine.
2 Remove the tower transport lock pin.
3 Raise the tower to a vertical position.
4 Check to be sure that each tower mounting boltis torqued in sequence to specification. Refer toSection 2, Specifications.
Bolt torque sequence
1
5
8
3
10
7
2
6
4
9
Tongue
-
8/11/2019 116478 - AL8000HT Light Tower
45/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 23
REV A
September 2008
CHECKLIST D PROCEDURES
5 Check to be sure that each bearing mountingbolt under the tower support is torqued insequence to specification. Refer to Section 2,Specifications.
Bolt torque sequence
D-3Replace the Hydraulic Return
Filter
Note: Terex requires that this procedure be
performed every 1000 hours or annually, whichevercomes first.
Replacement of the hydraulic return filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause themachine to perform poorly and continued use may
cause component damage. Extremely dirtyconditions may require that the filter be replaced
more often.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may causesevere burns.
1 Open the road side cabinet cover and locate the
hydraulic return filter next to the power unit.
2 Place a suitable container under the hydraulic
filter.
3 Clean the area around the filter. Remove the
filter with an oil filter wrench.
4 Apply a thin layer of fresh oil to the gasket ofthe new oil filter.
5 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled.
6 Pull out the red Emergency Stop button (if
equipped) to the on position located on the backpanel of the light tower cabinet.
7 Activate any tower function and inspect the filterand related components to be sure that thereare no leaks.
8 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter.
1
7
3
5
8
2
6
4
Tongue
-
8/11/2019 116478 - AL8000HT Light Tower
46/100
Section 3 Scheduled Maintenance Procedures
3 - 24 AL8000HT Light Tower Part No. 116478
REV A
September 2008
D-4Perform Engine Maintenance -
Isuzu Models
Note: Engine specifications require that this
procedure be performed every 1000 hours orannually, whichever comes first.
Required maintenance procedures and additional
engine information is available in theIsuzu 4LE1 Diesel Engine Instruction Manual
(Isuzu part number IDE-6033).
Isuzu 4LE1 Diesel Engine Instruction Manual
Terex part number 116133
CHECKLIST D PROCEDURES
D-5Perform Engine Maintenance -
Isuzu Models
Note: Engine specifications require that this
procedure be performed every 1250 hours.
Required maintenance procedures and additionalengine information is available in the
Isuzu 4LE1 Diesel Engine Instruction Manual(Isuzu part number IDE-6033).
Isuzu 4LE1 Diesel Engine Instruction Manual
Terex part number 116133
-
8/11/2019 116478 - AL8000HT Light Tower
47/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 25
REV A
September 2008
D-6Perform Engine Maintenance
Note: Engine specifications require that thisprocedure be performed every 1500 hours.
Required maintenance procedures and additional
engine information is available in theIsuzu 4LE1 Diesel Engine Instruction Manual(Isuzu part number IDE-6033) OR the
Kubota D-1105 and V-1505 Operator's Manual
(Kubota part number 16683-89169).
Isuzu 4LE1 Diesel Engine Instruction Manual
Terex part number 116133
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
CHECKLIST D PROCEDURES
D-7Perform Generator Maintenance
Note: Generator specifications require that thisprocedure be performed every 1500 hours orannually, whichever comes first.
Required maintenance procedures and additionalgenerator information is available in theLeroy Somer LSA 37 Installation and
Maintenance Manual (Leroy Somer part number
3664EN-09.2005/B) OR theMarathon Installation, Operation and MaintenanceManual(Marathon part number GPN012) OR the
Newage Installation, Service and MaintenanceManual(Newage part number BCH-018).
Leroy Somer LSA 37 Installation and
Maintenance Manual
Terex part number 116118
Marathon Installation, Operation
and Maintenance Manual
Terex part number 116188
Newage Installation, Service and
Maintenance Manual
Terex part number 830001
-
8/11/2019 116478 - AL8000HT Light Tower
48/100
Section 3 Scheduled Maintenance Procedures
3 - 26 AL8000HT Light Tower Part No. 116478
REV A
September 2008
D-8Perform Tongue Jack and
Outrigger Jack Maintenance
Note: Tongue and outrigger jack specifications
require that this procedure be performed annually.
Required maintenance procedures and additionalhitch information is available in the
Cequent Tongue Jack Use Manual(Cequent part number F3282ML).
Cequent Tongue Jack Use Manual
Terex part number 150140
CHECKLIST D PROCEDURES
D-9Perform Axle Maintenance
Note: Axle specifications require that this procedurebe performed annually or every 12,000 miles, whichever comes first.
Proper axle maintenance, following the axlemanufacturer's maintenance schedule, is essentialto good axle performance and service life. Failure
to perform the maintenance procedures can lead to
poor axle performance and component damage.
Required maintenance procedures and additionalaxle information is available in the Axis AxleOperator Maintenance Manual included with your
machine.
Axis Axle Operator Maintenance Manual
Terex part number 116117
-
8/11/2019 116478 - AL8000HT Light Tower
49/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 27
REV A
September 2008
Checklist E Procedures
E-1Test or Replace the Hydraulic Oil
Note: Terex requires that this procedure be
performed every 2000 hours or every two years,whichever comes first.
Replacement or testing of the hydraulic oil is
essential for good machine performance andservice life. Dirty oil and suction strainers may
cause the machine to perform poorly and continueduse may cause component damage. Extremely
dirty conditions may require oil changes to beperformed more often.
Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels of
contamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Open both cabinet covers.
2 Tag and disconnect the battery cables from thebattery.
Electrocution hazard. Contact with
electrically charged circuits couldresult in death or serious injury.
Remove all rings, watches andother jewelry.
3 Tag, disconnect and plug the hydraulic hosesfrom the power unit. Cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate andburn skin. Loosen hydraulic
connections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirt
or spray.
4 Tag and disconnect the electrical wiring andcables from the power unit.
5 Support and secure the power unit to a suitablelifting device.
6 Remove the fasteners securing the power unit tothe cabinet. Carefully remove the power unit
from the curb side of the machine.
Component damage hazard. Thehydraulic reservoir is plastic and
may become damaged if allowedto fall when removed from themachine.
7 Place a suitable container under the hydraulicreservoir. Refer to Section 2, Specificationsforcapacity specifications.
8 Remove the hydraulic reservoir retaining
fasteners from the power unit. Carefully removethe hydraulic reservoir from the power unit andcompletely drain it into a suitable container.
Bodily injury hazard. Beware of hotoil. Contact with hot oil may causesevere burns.
-
8/11/2019 116478 - AL8000HT Light Tower
50/100
Section 3 Scheduled Maintenance Procedures
3 - 28 AL8000HT Light Tower Part No. 116478
REV A
September 2008
CHECKLIST E PROCEDURES
9 Remove the suction strainer and clean it using amild solvent.
10 Rinse out the inside of the reservoir using a mild
solvent.
11 Install the suction strainer.
12 Install the hydraulic reservoir onto the powerunit.
13 Install the hydraulic reservoir retaining fasteners
and securely tighten. Do not overtighten.
14 Install the hydraulic power unit onto the
machine.15 Fill the reservoir with hydraulic oil to within a
1/2" from the top with the cylinders collapsed.
16 Clean up any oil that may have spilled. Properly
discard the used oil.
17 Operate all machine functions through a fullcycle and check for leaks.
18 Operate all machine functions through 5-10 fullcycles to fully remove air from the system.
19 Make sure unit is in a clear area during steps 17
and 18 as air in the cylinders can cause suddenmovements of the tower.
E-2Perform Engine Maintenance -
Kubota Models
Note: Engine specifications require that this
procedure be performed every 3000 hours.
Required maintenance procedures and additionalengine information is available in the
Kubota D-1105 and V-1505 Operator's Manual(Kubota part number 16683-89169).
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
-
8/11/2019 116478 - AL8000HT Light Tower
51/100
Section 3 Scheduled Maintenance Procedures
Part No. 116478 AL8000HT Light Tower 3 - 29
REV A
September 2008
E-3Perform Engine Maintenance -
Kubota Models
Note: Engine specifications require that this
procedure be performed every 2 years.
Required maintenance procedures and additionalengine information is available in the
Kubota D-1105 and V-1505 Operator's Manual(Kubota part number 16683-89169).
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
E-4Perform Generator Maintenance
Note: Generator specifications require that thisprocedure be performed every 4500 hours or every3 years, whichever comes first.
Required maintenance procedures and additionalgenerator information is available in theLeroy Somer LSA 37 Installation and
Maintenance Manual (Leroy Somer part number
3664EN-09.2005/B) OR theMarathon Installation, Operation and MaintenanceManual(Marathon part number GPN012) OR the
Newage Installation, Service and MaintenanceManual(Newage part number BCH-018).
Leroy Somer LSA 37 Installation and
Maintenance Manual
Terex part number 116118
Marathon Installation, Operation
and Maintenance Manual
Terex part number 116188
Newage Installation, Service and
Maintenance Manual
Terex part number 830001
CHECKLIST E PROCEDURES
-
8/11/2019 116478 - AL8000HT Light Tower
52/100
Section 3 Scheduled Maintenance Procedures
3 - 30 AL8000HT Light Tower Part No. 116478
REV A
September 2008
CHECKLIST E PROCEDURES
E-5Perform Generator Maintenance
Note: Generator specifications require that thisprocedure be performed every 15000 hours or every19 years, whichever comes first.
Required maintenance procedures and additionalgenerator information is available in theLeroy Somer LSA 37 Installation and
Maintenance Manual (Leroy Somer part number
3664EN-09.2005/B) OR theMarathon Installation, Operation and MaintenanceManual(Marathon part number GPN012) OR the
Newage Installation, Service and MaintenanceManual(Newage part number BCH-018).
Leroy Somer LSA 37 Installation and
Maintenance Manual
Terex part number 116118
Marathon Installation, Operation
and Maintenance Manual
Terex part number 116188
Newage Installation, Service and
Maintenance Manual
Terex part number 830001
-
8/11/2019 116478 - AL8000HT Light Tower
53/100
Section 4 Repair Procedures
Part No. 116478 AL8000HT Light Tower 4 - 1
September 2008
Repair Procedures
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.
Use only Terex approved replacement parts.
Read each procedure completely and adhere to
the instructions. Attempting shortcuts may
pr